Semiautomatic packaging machine

ABSTRACT

A semiautomatic packaging machine utilizes a single servo motor to rotate a belt around single track, providing linear motion to two opposing loaders attached to the belt. As one loader approaches a retrieval area, an operator manually positions an article or group of articles with a unit of packaging material onto an infeed conveyor. Upon sensing the presence of the material to be packaged, a sensor sends a signal to a processor. The processor controls the servo motor and an elevating component to adjust the horizontal and vertical position of the loader to synchronize the positions of the loader and the article(s). The loader removes the article(s) from the infeed conveyor, and transports them through a closer or other packaging element. The packaged articles are released into a discharge area as a second loader simultaneously approaches the retrieval area to repeat the process.

FIELD OF THE INVENTION

[0001] This invention relates generally to packaging machinery and processes, and in particular, to semiautomatic linear motion systems and processes incorporated in the packaging machinery for transporting articles though the packaging process.

BACKGROUND OF THE INVENTION

[0002] Articles, including manufactured and processed consumer goods and foodstuffs, are typically packaged in some way prior to delivery to the ultimate end user. To conserve materials, energy, and space, manufacturers and distributors generally attempt to package articles using just enough packaging materials to ensure that the articles are protected as well as easy to transport, store, and sell. To save time and labor, a variety of mechanical and electromechanical machines have been utilized to bundle, fill, sort, tie, seal, wrap, or otherwise package the articles.

[0003] Machines and processes for packaging articles are well known. One approach to packaging articles has been to use a manual packaging machine, in which an operator feeds an article or group of articles, usually one after another, into an infeed station. When the desired number of articles is in place, the operator manually operates the machine such that wrapping material is applied to the articles. Although in some instances, manual approaches can be effective, in bulk distribution operations, they can be labor-intensive and time consuming.

[0004] Another approach is to completely automate the packaging process with an automatic packaging machine. Articles are loaded in bulk along a forming line leading to the automatic packaging machine. Pusher elements push the articles along a conveyor at predetermined intervals, controlling the rate at which articles enter the automatic packaging machine and the number of articles to be wrapped together in a single package. A packaging material feeder unit dispenses packaging material, such as carton blanks. A loader mounted on a sliding track, or “slide” grasps the articles as the articles enter the packaging machine and guide the articles through the packaging process. The loader then returns to retrieve more articles.

[0005] To increase packaging speed, automatic packaging machines may use a dual slide system to transport the articles through the packaging process. In a dual slide system, a loader is mounted on each slide. Each slide requires a separate drive system, typically including a motor, a rotary controller, and associated components.

[0006] Many automatic packaging machines are of complex construction. Thus, to accommodate different packaging materials and the various sizes, shapes, and numbers of articles to be wrapped, automatic packaging machines require numerous adjustments to elements and timing, relatively sophisticated software, and well-trained operators. Machines that include a large number of moving parts also require frequent and complicated cleaning and maintenance. Moreover, due to their complexity, automatic packaging machines typically cost about 30 times as much as their manual counterparts.

[0007] There is a need for a less expensive and complicated alternative to fully automatic packaging approaches that is more efficient and less labor-intensive than manual packaging approaches.

SUMMARY OF THE INVENTION

[0008] Certain features and aspects of the various embodiments of the present invention address the problems described above by providing an efficient, less complex, and more cost-effective semiautomatic linear motion system. The semiautomatic linear motion system integrates with a variety of processing machines, such as a machine for packaging articles or groups of articles for transit, storage, sale, or other use. In the embodiments described, the semiautomatic linear motion system combines manual or automatic feeding, automatic conveyance, and an automated packaging process to achieve the efficiencies of fully automated packaging. The present invention requires fewer components, and thus, is less expensive to manufacture. The simplicity of the features and aspects of this invention makes the various embodiments of the invention easier to operate, maintain, and clean than fully automatic packaging machines, but faster and more efficient than a fully manual version.

[0009] Generally, various embodiments of the present invention include an apparatus for automatically or semi-automatically processing articles or groups of articles. The apparatus includes a single track and a single motor that is mounted to the track or to a frame that supports the apparatus. The motor provides rotational motion to one or more pulleys that rotate around an axis perpendicular to the length of the track. Variable parameters such as the speed and torque of the motor can be controlled by a rotary controller that communicates with a processor. A belt is looped or otherwise positioned around the track and is driven so as receives rotational motion from the motor, such that the belt revolves around the track. At least two loaders are coupled to the belt, such that each loader moves in unison with the belt.

[0010] An infeed conveyor is preferably below the track, positioned in a parallel and opposing manner with respect to the track. The infeed conveyor supplies a procession of articles or groups of articles to a retrieval area. The first loader transports an article or group of articles from a retrieval area, to a processing station, and then from the processing station into a discharge area. With respect to this invention, the processing station is essentially a “black box,” in that any type of process can be performed at the processing station, such as closing, capping, corking, wrapping, inspecting, weighing, marking, labeling, and assembling. The second loader, also coupled with the belt, directly opposes the first loader, such that the second loader moves in the opposite linear direction as the first loader as both loaders move in unison with the belt. The second loader transports another article or group of articles from the retrieval area as the first loader releases the first article or group of articles into the discharge area. The second loader then transports the second article or group of articles to the processing station, and from the processing station to a discharge area.

[0011] In certain embodiments the processing station is adapted to fasten a secondary packaging material to each article or group of articles, relative to a primary packaging material. Various embodiments also include a process for processing articles or groups of articles. The process includes the step of placing an article or group of articles on an infeed conveyor, which transports the first article or group of articles to the retrieval area. In semi-automatic versions of the invention the articles or groups of articles are placed on the infeed conveyor by hand. The operator also activates a processing machine that processes the first article or group of articles. The position of a first loader is synchronized with the position of the article or group of articles. The first loader is coupled with a belt positioned along the track. Therefore, the position of the first loader is synchronized by controlling the speed of the single motor that drives the belt and/or by controlling the speed of the infeed conveyor. The first loader can also be raised or lowered using and elevating member. The first loader transports the article or group of articles to a processing station, such as closer, and then transports the article or group of articles to a discharge area, where the article or group of articles is released. A second loader simultaneously travels to the retrieval area to transport a second article or group of articles to the processing station, the second loader being coupled with the belt, and positioned directly opposite the first loader. The processor may also control the vertical positions of the loaders using elevating elements.

[0012] The features and aspects of the various embodiments are described primarily with respect to packaging, but are equally advantageous in combination with machines that perform other tasks, such as wrapping, marking, labeling, inspection, and assembly.

[0013] According to certain aspects of the invention, the semiautomatic linear motion system uses a single servo motor to rotate a belt around single track, thereby providing linear motion to loaders attached to the belt. The loaders simultaneously transport articles through various areas of the machine, increasing the speed at which articles are processed without increasing the complexity of machine.

[0014] Various embodiments of the semiautomatic linear motion system (SLMS) transport articles through a packaging process using at least two opposing loaders. The loaders are coupled to a belt that revolves around a single track. Certain aspects of this feature allow at least two articles or groups of articles to be processed simultaneously without the need for two tracks driven by multiple motors. The belt is looped around the track and is associated with a single motor, which is driven by a rotary controller. The rotary controller can be any appropriate motion control device, such as an adjustable speed drive, servo driver, or stepper rotary controller. At least two loaders are attached to the belt. The motor is first activated preferably when a sensor, such as an infrared or ultrasonic sound detector, senses the presence of an unpackaged article or group of articles. A processor detects the output of the sensing element, and directs the motor to synchronize the position of a first loader with the unpackaged article or group of articles. The horizontal and vertical position of the first loader is adjusted to retrieve an unpackaged article or group of articles from a retrieval area, while a second loader delivers a packaged article or group of articles to a discharge area. The first loader proceeds in a working direction away from the input end of the frame and toward the output end of the frame, and into the packaging mechanism. The packaging mechanism may enclose the article or group of articles in a flexible wrapper, carton, or other package. Simultaneously, the second loader proceeds in a retrieval direction toward the input end of the frame to retrieve the next article or group of articles.

[0015] As compared to other servo belt loader style machines, various embodiments of this invention eliminate the need to process one article or group of articles at a time, or to have more than one track. Rather, as a first loader retrieves an article or group of articles from the infeed conveyor, another loader attached to the same track simultaneously transports another article or group of articles through the packaging process.

[0016] Another aspect of various systems and processes of the present invention is the incorporation of loaders with the capacity to each transport multiple articles to be packaged in a single package.

[0017] Certain embodiments of systems and processes of the present invention have the advantage of automatically synchronizing operation with the presence of articles to be packaged. This feature allows implementation even in somewhat erratic processing environments, such as where articles come available for a packaging at intervals that vary in duration.

[0018] These and other objects, features, and/or advantages accrue from various aspects of embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is an perspective view of a packaging machine that incorporates various aspects of certain embodiments of the invention;

[0020]FIG. 2 is an perspective view of a loader according to certain embodiments of the invention;

[0021]FIG. 3a is a top view of a semiautomatic linear motion system incorporating various aspects of certain embodiments of the invention; and

[0022]FIG. 3b is a side view of a semiautomatic linear motion system incorporating various aspects of certain embodiments of the invention.

[0023]FIG. 1 is an illustration of a wrapping machine that includes a semiautomatic linear motion system (SLMS) 100, according to one embodiment of the invention. Certain embodiments of the SLMS 100 are supported by a frame 102. The frame has an input end 104 and an output end 105. A single motor 106, such as a servo or stepper motor, is mounted and fixed with respect to the frame 102. In certain embodiments, the motor 106 is controlled by a rotary controller (not shown). A belt 108 is closed in a loop around a track 110. The track 110 is mounted along the length of the frame 102. In the embodiment shown, the track 110 is substantially rectangular with rounded ends, although other configurations of the track 110 are possible, including oval or circular. The motor 106 is associated with the belt 108 via relative pairs of pulleys 109 so as to provide rotary motion to the belt 108, causing the belt to revolve around the track 110. At least two loaders 112, 112′ are positioned, preferably on or near the outer surface of the belt 108 so as to travel in concert with the belt 108.

[0024] An advantageous aspect of the various embodiments of the SLMS 100 is the use of the single motor 106 to drive the belt 108. This aspect simplifies the systems and processes of the invention, without reducing the efficiency of the invention. While one article or group of articles is being packaged, another article or group of articles is being positioned at the input end 104. As the first article or group of articles is released, the second article or group of articles is transported into position for retrieval by a loader 112, 112′. The single motor 106 can be any suitable device for providing rotational motion, such as a servo, stepper, or stepless motor. The motor 106 is controlled by a rotary controller (not shown). Examples of rotary controllers include servo drives, stepper motor controllers, and adjustable speed drives.

[0025]FIG. 2 illustrates certain aspects of a loader according to various embodiments of the invention. Each loader 112 is coupled with the belt 108 preferably with a clamp, although alternative attaching members 114 include but are not limited to adhesives, staples, studs, rivets, and banding. An elevating member 115 may be interposed between the loader and the attaching members 114. Examples or components of elevating members 114 include but are not limited to pick-and-place handling devices, hydraulic or pneumatic lifting devices, vacuum handling devices, jaw grippers, rotary actuators, hoists, winches, scissor lifts, reversible motors, and robotic arms.

[0026] Referring again to FIG. 1, a product staging area 116 is located near and may project out of an end of the frame 102, immediately adjacent to an infeed conveyor 118 that leads to a sensing position 120. The infeed conveyor 118 can be any sort of moving or propelling surface, such as powered or gravity belt conveyors, wheel conveyors, and roller bed conveyors.

[0027] A sensor 122, preferably a photonic, sonic, or electronic sensing device such as a silicon photodiode, ultrasonic transducer, interrupter, or cable extension transducer is positioned and aimed to sense the presence of materials at the sensing position 120. Upon sensing the presence of materials at the sensing position 120, the sensor 122 signals a processor. The signal from the sensor 122 can include data detailing the position and dimensions of the materials. The signals received from the sensor enable the processor to send commands to the rotary controller and to systems controlling the motion of the infeed conveyor 118 and the elevating members 114.

[0028] A control panel 126 also communicates with the processor so as to electronically control the speed and other mechanical parameters of the SLMS 100. Information communicated from the control panel 126 includes instructions and other inputs provided by the operator.

[0029] The term “product” describes an article or group of articles to be prepared for transit, storage, or sale, by being packaged into a single packaged unit, such as a case, crate, tray, shrinkwrap pack, bundle or multipack. Product 128 typically includes a primary packaging material. For instance, assume the product to be packaged using an embodiment of the invention is margarine. Each article of margarine is encased in a primary packaging material, such as a plastic tub. Certain embodiments of the invention package the product 128 by applying a secondary packaging material, for instance to transform a group of articles into one multipack containing two or more tubs of margarine. The primary packaging material may include a can, box, case, wrap, carton, fabric, binding material, or the hardened exterior shell, casing, body, skin, peel, husk, or other protective layer of the article.

[0030] According to certain aspects of the present invention, product 128 is packaged as follows. An operator places the product 128 on a staging plate 130 in the product staging area 116. Secondary packaging material 132 is positioned, such as by loosely placing a single unit of secondary packaging material 132 in contact with the product 128 to be packaged. The secondary packaging material 132 can be positioned manually, such as by a human operator, or automatically, such as by a packaging material feeder unit (not shown). The operator then slides the product 128 onto the infeed conveyor 118. The speed of the infeed conveyor 118 can be preset by the operator, preferably via the control panel 126. The control panel 126 can include or interact with a user interface, such as computer display and/or manual switches, knobs, joysticks, pedals, and other controls. The user interface and/or control panel can be physically attached to the SLMS 100, or can be remotely accessed.

[0031] When the product 128 reaches the sensing position 120, the sensor 122 senses the presence and/or dimensions of the product 128, which triggers a loader 112 to synchronize its position with the position of the product 128. The loader 112 may also use dimensional data provided by the sensor to adjust the “grip” of the loader 112, so that the loader 112 can retrieve articles of various sizes and shapes. Preferably, the loader 112 tracks the product 128 very closely, such as within a tolerance of about ¼ inch. To do so, the motor 106 must adjust its speed to align the loader 112 with the product in the horizontal plane.

[0032]FIG. 3a is a top view that illustrates the opposing nature of dual loader embodiments of the present invention. As the motor 106 synchronizes the loader 112 with the product, the second loader 112′ travels at the same rate in a direction opposite to the first loader 112.

[0033] According to various aspects of this embodiment, the loader 112 is preferably at least partially synchronized with the product 128 in the vertical plane. FIG. 3b is a side view of a semiautomatic linear motion system incorporating various aspects of an embodiment of the invention. FIG. 3b illustrates one version of an elevating member 115 that is interposed between the loader 112 and the attaching member 114. When synchronizing with a product 128, the elevating member 115 lowers the loader 112 such that the loader 112 contacts the product 128 and/or secondary packaging material 132. When synchronization of the loader 112 and the product 128 is achieved, the loader 112 grasps or otherwise contacts the secondary packaging material 132 and the product 128, at least partially wrapping the secondary packaging material 132 around the product 128. After grasping, the loader 112 may be raised or lowered as needed to transport the product 128 to a processing station 134.

[0034] According to the embodiment shown in FIG. 1, the processing station 134 includes a packaging element, such as a closer unit. The loader 112 transports the product 128 to the processing station 134. The packaging element shown closes the package by securing the secondary packaging material 132 onto the product 128, such as by fold closing, tuck closing, crimp closing, weld sealing, fusion sealing, solder sealing, heat sealing, blister sealing, or induction sealing the secondary packaging material 132 that has at least in part been wrapped around the product by the loader. The loader 112 then releases the finished package such that the finished package enters the discharge area 136 at the output end 105 of the frame 102. A second loader 112′ simultaneously arrives at the input end 104 of the frame 102 to retrieve another product 128 from the infeed conveyor 118. Each loader 112, 112′ is preferably raised into a retracted position by the elevating member 115 to reduce air resistance as the loader 112, 112′ travels in a nonworking direction.

[0035] If the operator has positioned the second product 128 on the staging plate 130 and has slid the product 128 onto the infeed conveyor 118, the infeed conveyor 118 transports the product 128 to the sensing position 120. Upon sensing the product 128, the processor signals the motor 106 and the elevating member 115 to adjust the speed and elevation of the second loader 112′ so as to synchronize the second loader 112′ with the product.

[0036] According to various aspects of the embodiments of the invention, the process of packaging a large quantity of product 128 into multiple packages proceeds in a continuous fashion. As long as the operator and the closing unit keep pace with the SLMS 100, no interruptions in the process are required. In other words, while a first product 128 is being packaged, the operator must prepare a second product 128 and feed the second product 128 onto the infeed conveyor 118. If the second product 128 reaches the sensing position 120 before packaging of the first product 128 has been completed, the second product 128 can be held at the sensing position 120 until a loader 112 is available to retrieve the second product 128. Holding can be accomplished by pausing the infeed conveyor 118, or by physically delaying the progression of the second product 128. Thus, small variations in the operator's loading of product 128 into the packaging machine will not disturb the process. Advantageously, the SLMS 100 can be programmed to automatically pause either or both the belt 108 and the infeed conveyor 118 if no product 128 is present either at the sensing position 120 or in either of the loaders 112. This aspect of various embodiments of the invention enables its use in environments in which the availability of product 128 is erratic, such as where each article is hand assembled prior to packaging.

[0037] The foregoing description of various aspects, features, and embodiments of the invention has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching. For example, it should be understood that although the present invention has been described primarily as it relates to cartoning, the principles of the invention can be implemented with any type of packaging or processing, including but not limited to wrapping, capping, and corking. As another example, the various aspects of the invention are compatible with various horizontal, vertical, spiral, or other packaging machines. The number of loaders is limited only by the speed of the packaging machine. The motor may also be bidirectional. Additional applications include intermittent motion hand packaging machines and hand load cartoners. Further, in addition to packaging, the invention is directed to systems and methods that can be implemented in any appropriate environment, independent of the process implemented, such as inspection, marking, labeling, and assembly. 

What is claimed is:
 1. An apparatus for packaging articles or groups of articles, comprising: (a) a single track; (b) a single motor fixed with respect to the track, the motor providing rotational motion around an axis perpendicular to the length of the track; (c) a belt positioned around the track, and driven by the motor; (d) an infeed conveyor parallel to the track, and adapted to supply a procession of articles or groups of articles to a retrieval area, each article or group of articles including a primary packaging material; (e) a processing station adapted to fasten a secondary packaging material relative to the primary packaging material; (f) a first loader, being coupled with the belt such that the first loader rotates along with the belt, the first loader being adapted to: (i) transport a first article or group of articles from the retrieval area; (ii) transport the article or group of articles from the processing station; and (iii) release the article or group of articles into a discharge area; and (g) a second loader, being coupled with the belt such that the second loader rotates along with the belt, and directly opposes the first loader, the second loader being adapted to: (i) transport a second article or group of articles from the retrieval area as the first loader releases the first article or group of articles into the discharge area; (ii) transport the second article or group of articles to the processing station; (iii) transport the second article or group of article from the processing station; and (iv) release the second article or group of articles into a discharge area.
 2. The apparatus of claim 1, wherein the procession of articles or groups of articles is manually loaded onto the infeed conveyor.
 3. The apparatus of claim 1, further comprising: (h) a sensor, adapted to sense the position of each article or group of articles at a sensing position and to communicate the position of the article or group of articles to a processor; and (i) a processor, adapted to control the speed of the single motor according to the position of the article or group of articles.
 4. The apparatus of claim 3, wherein the processor is further adapted to control the vertical position of each of the first and second loaders according to the position of each article or group of articles.
 5. The apparatus of claim 4, wherein the processor controls the vertical position of the first loader and of the second loader by controlling the operation of a first elevating member coupled with the first loader and a second elevating member coupled with the second loader.
 6. The apparatus of claim 3, wherein the processor is further adapted to control the speed of the infeed conveyor according to the position of each article or group of articles.
 7. The apparatus of claim 1, further comprising a packaging material feeder unit for automatically dispensing secondary packaging material.
 8. The apparatus of claim 7, wherein the packaging material feeder unit is adapted to automatically place the secondary packaging material in contact with each article or group of articles.
 9. The apparatus of claim 1, wherein the first loader and the second loader are each adapted to form the secondary packaging material at least partially around each article or group of articles.
 10. The apparatus of claim 1, wherein the processing station is a component of a cartoning machine.
 11. The apparatus of claim 1, wherein the processing station is component of a wrapping machine.
 12. The apparatus of claim 1, wherein the processing station is component of a closing machine.
 13. The apparatus of claim 1, wherein the processing station is component of a marking machine.
 14. The apparatus of claim 1, wherein the processing station is component of a capping machine.
 15. The apparatus of claim 1, wherein the processing station is component of a product inspection machine.
 16. An article or group of articles packaged using the apparatus of claim
 1. 17. A process for packaging articles or groups of articles, each article or group of articles including a primary packaging material, the process comprising: a) placing a first article or group of articles on an infeed conveyor, the infeed conveyor being adapted to transport the first article or group of articles to a retrieval area; and b) activating packaging machine that packages the first article or group of articles by: (i) synchronizing the position of a first loader with the position of the first article or group of articles, the first loader being coupled with a belt positioned along a single track, the belt being driven by a single motor; (ii) using the first loader, transporting the first article or group of articles to a processing station, the processing station being adapted to fasten a secondary packaging material relative to the primary packaging material; (iii) transporting the first article or group of articles to a discharge area; and (iv) releasing the first article or group of articles at the discharge area, while a second loader simultaneously travels to the retrieval area to transport a second article or group of articles to the processing station, the second loader being coupled with the belt directly opposite the first loader.
 18. The process of claim 17, wherein synchronizing the position of the first loader with the position of the first article or group of articles comprises: (1) sensing the position of the first article or group of articles; (2) communicating the position of the first article or group of articles from the sensor to a processor; and (3) adjusting the speed of the motor according to the position of the first article or group of articles.
 19. The process of claim 18, further comprising: (4) adjusting the elevation of the first loader according to the position of the first article or group of articles
 20. The process of claim 17, wherein synchronizing the position of the first loader with the position of the first article or group of articles comprises: (1) sensing the position of the first article or group of articles; (2) communicating the position of the first article or group of articles from the sensor to a processor; and (3) adjusting the speed of the infeed conveyor according to the position of the first article or group of articles.
 21. The process of claim 17, wherein activating the packaging machine further comprises: (v) positioning secondary packaging material in contact with each article or group of articles prior to transporting the article or group of articles to the processing station.
 22. An article or group of articles packaged according to the process of claim
 17. 23. A machine for packaging articles or groups of articles, comprising: (a) a frame; (b) a single track mounted along the length of the frame; (c) a single motor fixed with respect to the frame, the motor being adapted to rotate at least one of a plurality of pulleys around an axis perpendicular to the length of the frame; (d) a belt positioned around the track, and associated with the pulleys so as to be driven by the motor; (e) an infeed conveyor opposing and parallel to the track, the infeed conveyor being adapted to transport each article or group of articles to a retrieval area; (f) a sensor for sending a first signal to a processor to indicate the presence of a first article or group of articles at a sensing position; (g) a processor for synchronizing the position of a first loader with the first article or group of articles in response to the signal from the processor; (h) a packaging element adapted to fasten a packaging material relative to the article or group of articles; (i) a first loader coupled with the belt such that the first loader moves in unison with the belt, for: (i) transporting the article or group of articles from the retrieval area to a packaging element; and (ii) transporting the article or group of articles from the packaging element to a discharge area; and (j) a second loader coupled with the belt such that the second loader moves in unison with the belt and directly opposes the first loader, for: (i) traveling towards the retrieval area as the first loader travels toward the discharge area; (ii) transporting a second article or group of articles to the packaging element; and (iii) transporting the second article or group of article from the packaging element to the discharge area.
 24. The machine of claim 23, wherein: the sensor is further for sending a second signal to a processor to indicate the presence of the second article or group of articles at the sensing position; and the processor is further for synchronizing the position of a second loader with the second article or group of articles in response to the second signal from the processor;
 25. The machine of claim 24, wherein the processor synchronizes the position of the first loader and the second loader by adjusting the speed of the single motor.
 26. The machine of claim 24, wherein the processor synchronizes the position of the first loader and the second loader by adjusting the speed of the infeed conveyor.
 27. The machine of claim 24, wherein the processor synchronizes the position of the first loader and the second loader by controlling the operation of a first elevating member coupled with the first loader and by controlling the operation of a second elevating member coupled with the second loader.
 28. A package packaged using the machine of claim
 23. 